Improved carbohydrate-phenol resin and process of making same



Patented Sept. 13, 1932 UNITED STATES PATENT oar-"l ce aosnrn v. MEIGS, or 31200111311, NEW YORK, ASSIGNOB, BY rmsnn Assrenm'rs, 1'0

IPLASTIX CORPORATION, A CORPORATION or DELAWARE IMPROVED cAnnonynn'A'rn-rrmnon RESIN AND rnocnss or MAKING slum No Drawing.

This invention relates to artificial resins, especially to carbohydrate-phenol resins and intended for use in the manufacture of molded or pressed articles, impregnated substances or structures, orjvarnishes, or for other purposes for which products of this general type are used. 7

One of the objects of the invention is to provide resinous products possessing mechanical strength of a high order together with an increased resistance to water and improved electrical insulating properties under conditions involving the presence of water. Another object is to increase the speed with which such resins may be hardened or rendered infusible. These and other objects will be more fully hereinafter described. 1

In the preferred form of the present invention I use the primary resins, that is the 3O resins at the soluble and fusible stage, made as described in my U. S. Patent No. 1,593,342,

issued July 20, 1926, and in my copending application Serial No. 92,640, filed March 5,

1926; although I may use other resins, as for example, the primary resins described in my United States Patents Nos. 1,845,314, granted February 16,1932; 1,832,038, granted N ovem-' ber 17, 1931; 1,801,052, granted April 14,

1931; 1,801,053, granted April 14, 1931; or

fusible and soluble carbohydrate-phenol resins incorporating fatty acids or oilsas described in my copending application Serial No. 161,468, filed January 15, 1927.

In carryin out the invention in its preferred form, select a relatively brittle, fusi ble carbohydrate-phenol resin and treat it with a suitable proportion ofa reactive metallic basic body, as for example, five to twenty-five per cent by weight of calcium hyfi 1 droxide and simultaneously w th, or prior to or subsequent to this treatment I inco 0- rate a sufficient proportion of hardening agent, preferably formaldehyde or derivatives thereof, to enable such resin to become infusible and mechanically strong when Application filed November 10, 1927. Serial No. 282,459.

heated Supporting, extending or other material of'a desirable character may be-incorporated at any suitable stage of the process by various means known in the art Such material may be fibrous, cellular, amorphous or crystalline in character. v1 1.1-

The metallic basic bodies'used in the present invention may be divided intotwo broad classes, viz., those freely soluble in water and those not'freely soluble "or insoluble. The

former class includes thehydroxides o'f thei.

alkali metals and the latter: group embraces compounds of the alkalina fiearth metals, the earth metals and the so-calld heavy metals.

I may use, as examples of the latter group the oxides or hydroxides of calcium,-barium,"

uct possessing electrical insulatingpropen ties much superior, especialyninder conditions involving moisture, to thd'se characteristic of the same resin acted on by the formaldehyde derivative in the absence ofthe metallic basic compound. i i I r In a typical case, the insulation resistance of an infusible resinous heating a mixture of car ohydrate' phenol resin, wood flour and hexa (hexamet ylene 'tetramine) was increased approximately ten fold by including a substantial proportion calcium hydroxlde in the composit1on. theinstance referred to the value of the insulation resistance was measured after exposproductv made ,by

' ing the product is an efiicient opinion,

' with hexamethylene tetramine,

p base. Any of to a humidity of 90 per cent for five days and therefore constitutes a measure of the ability of the resinous product to withstand the action of moisture. At the same time, the value of the product as a dielectric insulating medium, measured 1n termsof dielectric constant and phase angle difference, was improved more than one hun dred per cent.

Hexamethylehe tetramine (hexa' so-called) hardening agent for carbohydrate phenol resins in under suitable conditions products 9. hi i h order of mechanical strengt but has the disadvantage that it also produces products'which are more susceptible to water than is desired and which do not, particularly under conditions involving moisture, possess ashigl'ra degree of electrical insulating value asdesir'ed' for some uses. This disadvantage of hexamethylene; tetramine, when applied to carbohydrate phenol resins, 18 due, in my to the presence insueh resins of organic acids, probably humic acids-0r cleriyatives thereof, which are capable of reactmg nia therefrom, toform water soluble or water decomposable products. The deleterious etfeht of ammonia on carbohydrate phenol resins is readily. demonstrated by actual test as described in my copending application Serial No. 161,469 filed January 15, 1927.

I have, however, overcome this disadvantage by using a metallic compound 1n conjunction withhexamethylene tetramine, and mud that this combination imparts not only suitable mechanical strength but also electrical insulating value and water res stance of a hi h order.

A p'ri ssible explanation of the benefits thus obtained is that those constituents of the resin which otherwise react with ammonia (or hexamethylene tetramine), may first react with the metallic base and thus become inert toward ammonia, or, the metallic base may liberate ammonia from its union with the resin. It is also'possible that the water solu ble or water-decomposable reaction products of the resin and ammonia (or I tetramine) may form a water insoluble addition product of a physico-chemical character or a chemical character with the metallic these or equivalent to be understood as meant by the term der vative employed in the claims. My observations appear toindicate that electrical insulating value and water resistance are highest when the quantity of metallic base is at least approximately chemically equivalent to the ammonia capableof being yielded by the hexamethylene tetramine.

'The advantages accruing to the use of a metallic compoundin conjunction with a methylene amine as described ma be noted by reference to the following ta le, which the sense that it yields ossessing" or the ammohexamethylene eiiects are.

refers to molded compositions containing Table No -2 No. 1 Composition gfi gfi with hexa- 1 methylene methyl? tetmmine tetrarnme and calcium ynmfiut ca cium yhydroxide dmxide Insulation resistance 319 to 525 40 megohnis megohms (or less) Dielectric constant 3. 0 4. Phase angle difierence (at 1000 cycles). 2.0 degrees- 3.5 degrees. Product of dielectric constant multi- 6.0 14.4.

plied by phase angle difference. Transverse breaking strength in 10,600 9,000 to 10,000

pounds per square inch of cross secion.

It will be seen that the composition using methylene amine are brown, whereas in the absence of such metallic base the color is much darker, usually black, although perhaps not quite jet. From my observations, this bleachin g-efi'ect appears to be due to a mutual action of the reactive metallic compound, and the methylene amine,.or ammonia, on the resin. This is an important discoveryin view of the demand for molded or pressed products with colors other than black.

4 Still another advantage due to the combined use of a metallic compound and a hardening agent, particularly a methylene hardening agent, as I applied to a carbohydrate phenol resin, is an increase in the rate of curing (hardening). The metallic compound appears to activate the methylene compound. This has been observed in particular in the case of hexamethylene tetramine when used with lime.

The invention may be practiced in various ways. For example: (1) A fusible rosin may be mixed with a metallic base, an-aldehydic or methylene hardening agent such as the methylene amine, hexamethylene tetramine, and filling material, first in a. ball mill and subsequently on heated rolls. (2) A solu tion of the resin in a solvent such as alcohol may be mixed with a hardening agent, metallic base and filling material and the solvent 11'? then evaporated or distilled. The resin resin; and the resulting product then mixed with the hardening agent, and with the filling material, if used, :eitherby the dry method, or by using a solvent. Other modifications will suggest themselves to those skilled in the resin art. Such procedures will yield compounds suitable' for molding. The filling material is generally of a comminuted nature and often cellular or fibrous, such as wood flour, cotton flock, or other forms of, cellulose.

Impregnated or coated paper or fabric is prepared by substantially the same method, the filling material beinghowever in sheet form instead of in a comminuted condition. This difference necessitates a somewhat different technique in applying the resin to the filling material. It ispossible to heat the resin with a suitable metallic compound, dissolve such product in a volatile solvent, together with the'hardening agent, as for example hexamethylene tetramine, and then use the resulting varnish as an impregnating or coating medium for application to paper or fabric. Equivalent results might be obtained by preparing a paper or fabric loaded with suitable proportions of metallic base, and then impregnating or coating such paper or fabric with a solution of resin containing an appropriate hardening agent.

For the preparation of molding material one may proceed in a typicalcase as follows:

Example 1 p v In a ball mill pulverize and grind together 1000 grams of a primary carbohydrate phenol resin, such as the primary or soluble and fusible resins described in Patent No. 1,593,342, together with 120 grams of calcium hydroxide and 150 grams of liexamethylene tetramine. To this mixture add 1400 grams of wood flour and continue grinding until the mixture is uniform and the wood flour particles are coated with the finely pulverized resin mixture. Pass the mixture in portions through differential rolls heated to to .100 degrees centrigrade, taking care to remove each portion from the rolls while it is still capable of readily flowing when subsequently molded. When all has been compacted and amalgamated by the hot rolls, disintegrate to a coarse or fine powder as desired and mold at'a temperature of 150 to 180 degrees centrigrate under pressure in the manner customary for hot molded or heat-set products.

- I am not limited to the precise proportions of metallic compound indicated. The proportions specifically describedherein are for illustrative purposes only", Some carbohy drate phenol resins 'may containfree sulphuric acid or other equivalent substance used as a convertingagent in the reaction between carbohydrate and phenol, and in such salts of fatty acids.

case I use more thanenough metallic compound to react with such acid converting agent. Where the hardening agent is a methylene amine, I may, as already described, advantageously use su-fiicient metallic com pound to bechemieally equivalentto the ammonia or amine capable of being yielded by such hardening agent. Nor am 1; limited to any particular metallic compound. I

' have obtained good results by using the more 'diflicultly water solublemetallichydroxides a or corresponding oxides, butlI mayduse" any metallic compound sufiicitentlybasic' or reactive to effect the improvements herein idescribed. In some cases I can use themetallic I am aware of proposals to neutralize mineral acid catalysts in phenolic resins by bases including metallic bases and then to heat the product with a formaldehyde derivative, and wish to. point out that my invention is quite different. In such procedures the mineral acid is converted into a metallic jderivative but the organic resinous constituents are ,unaffected. My object is to have enough reactive basic compound to form a derivative with certain organic constituents ofIthe resin and the methylene amine hardening agent. In my method, the neutralization of any mineral acid which may be present is merely incidental. e

The condensation product of ammonia and formaldehyde herein called hexamethylene tetramine is the hardeningagent I prefer,

but the invention is not restri cted,thereto,as- 11 I may use any othcrsuitable hardener, Such as trioxymethylene, condensation products of formaldehyde and aromatic amines and other compounds, which 1n conjunction with a metallicbase, act on carbohydrate phenol resins to produce products possessing mechanical strength of a high order coupled wlth superior resistanceto' water and im-' proved electrical insulating properties, as

herein described. V p 1 The property herein described as insulhtion resistance was determined in they following manner:

The samples were 12.5 centimeters. long,

1.3 centimeters wide and 1.3 cfiitimeters thick. Brass strips wrapped withtinfoil were used as electrodes. Each electrode con sisted of twostrips between which the sample was clamped. Two such electrodes were placed on each sample 2.6 centimeters apart. The tinfoil along the edge of each electrode was pressed down against the surfaceofthe sample with the dull edge of a knife in order to insure good contact with the surface. The samples, were placed in a humidity chamber in which the relative humiditywas kept con stant zit-'90 per cent humidity by means of a sulphuric acid mixture ofthe propers p'ecific gravity. At the end of five days, measurements of the electrical resistance between the electrodes as described.

The term high insulation resistance is a relative one and'refers to the improvements as herein described. The same thing is true of the term water resistant. The term mechanical strength of a high order refers to values for modulus of rupture or transverse breaking strength in the neighborhood of 8000 pounds per square inch or more.

I have found that glycerine may be used as hardening agent for carbohydrate phenol resins.- I have reacted gylcerine with such resins and thereby changed fusible resins to the infusible state. The following example may be cited as an illustration.

Example 92 'A carbohydrate phenol resin of the type referred to as a primary resin in Example 1, was distilled until the temperature of the resin reached 230 degrees centigrade. Free phenol was evolved and condensed. To the residue, about 16 per cent of glyccrine was added and distillation continued, the temperature of the mass rising from 214 to 260 degrees centigrade during about two and one half hours. At the end of this time the resin became infusible and resilient.

The slow rate of hardening noted in Example 2 suggests the application of this reaction in the production of resinous products that are molded and subsequently baked to harden, i. e. in the cold molding art. In such application, the gylcerine or equivalent will act as afluxfor the molding operation and as a hardening agent in the subsequent baking. As is well known in the cold molding art, the molding mixtures vshould be plastic during molding and it is desirable that plasticising agents combine chemically during the subsequent baking. It would appear that g1 cerine may perform these functions.

Vhile my invention in its preferred form involves the use of a metallic base in conjunction with a methylene hardening agent, I may in some cases, especially with resinous products the properties of which do not re quire the use of such hardening agent, dispense with the employment of the same. The

following example is an illustration. In this example aniline with hydrochloric acid is used as a converting agent and it is to be understood that other converting agentsmay be employed as for example sulphuric acid.

Example 3 A reaction mixture consisting of Argo corn sugar (crude dextrose) 420 grams, metapara cresol 180 com., water 100 cubic centimeters, aniline 30 cubic centimeters, and concentrated hydrochloric acid 8 cubic centimeters was boiledunder a reflux condenser for five hours, the reflux condenser being cooled by a flow of cool water at ordinary temperature. An aqueous solution and a resinous product were formed. The latter. was removed and washed with hot water. 15 grams of lead dioxide were incorporated with the washed resinous product, without dehydrating the latter, and the resulting mass heated. At about 14.0 degrees F. there was a sudden coagulation. \Vater separated and a tough rubbery mass was produced.

\Vhat I claim is:

1. The reaction product of a carbohydrate phenol resin, a hardening agent and a compound of the group consisting of oxides and hydroxides of metals.

2. The reaction product of a carbohydrate phenol resin, a methylene hardening agent and a compound of the group consisting of oxides and hydroxides of metals.

3. The reaction product of a carbohydrate phenol resin, a methylene amine hardening agent and a compound of the group consisting of oxides and hydroxides of metals.

4. The reaction product of a carbohydrate phenol resin, hcxaniethylene tetramine and a compound of the g1 oup consisting of oxides and hydroxides of metals.

5. The reaction product of a carbohydrate phenol resin, calcium hydroxide and hexamethylenc tetramiue.

6. The intusible reaction product of a carbohydrate phenol resin, a formaldehyde yielding substance and calcium hydroxide.

7. The iufusible reaction product of a carbohydrate phenol I resin, a formaldehyde yielding substance and an hydroxide of a metal of the alkaline earth group.

8. The infusible reaction product of a carbohydrate phenol resin, a formaldehyde yielding substance and a compound of the group consisting of oxides and hydroxides of metals.

9. The infusible reaction product of a carbohydrate phenol resin, amethylene amine hardening agent and a metallic hydroxide.

10. The infusiblc reaction product of a carbohydratc phenol resin, hexamethylene tetramine and an hydroxide of a metal of the alkaline earth group.

11. The infusible reaction product of a carbohydrate phenol resin, hexamethylene tetramine and a metallic hydroxide.

'12. A composition adapted for molding or 1 methylene tetramine and a compound of the group consisting of oxides and hydroxides of meta s.

16. A composition adapted for molding or pressing comprising a potentially reactive mixture of a carbohydrate phenol resin, hexamethylene tetramine and calcium hydroxide.

17. The process of making a resinous substance which comprises reacting by heating a carbohydrate phenol resin with a hardening agent and a com pound'of the group consisting of oxides and hydroxides of metals.

18. The process of making a resinous substance which comprises reacting by heating a carbohydrate phenol resin with a methylene amine hardening agent and a compound of the group consisting of oxides and hydroxides of metals.

19. The process which comprises reacting by heating a, carbohydrate phenol resin with a methylene amine hardening agent and a compound of the group consisting of oxides and hydroxides of metals and obtaining an infusible product possessing mechanical strengthof a high order and high insulation resistance.

20. The process which comprises reacting by heating a carbohydrate phenol resin with a metallic compound comprising calcium hydroxide and with hexamethylene tetramine and obtaining an infusible product possessing mechanical strength of a high order and high insulation resistance.

21. The process which comprises mixing substantially 1000 parts, by weight, of a fusible carbohydrate phenol resin with 120 parts of calcium hydroxide, 150 parts ofhexamet-hylene tetramine and 1400 parts of cellulosic material and subjecting the mixture to pres sure and heat at a temperature of from to centrigrade, disintegrating the product and subjecting the-same to pressure at a temperature of from to centigrade to produce infusibility.

. Y J OSPEH V. MEIGS. 

